HOW IT CREATES A FUTURE- PROOF TYRE MANUFACTURING…

Conventional tyre manufacturing systems require too much human skill and intervention, so the impact and consequences of digitalisation on the tyre industry are even greater. Standard manufacturing processes require strict monitoring, corrections and automation at every stage. Digitalisation offers numerous benefits for sustainable production improvements. They achieve measurable results in manufacturing, quality improvement, marketing and sales.

Tyre manufacturers monitor and automate their processes, reduce manual labour and gain real-time insights into production line status and performance. Barcode and QR code labelling streamlines production processes, enables efficient and cost-effective tracking and improves accuracy and efficiency. Traceability is simple and feasible, improving profitability and customer satisfaction.

Scanning simplifies the location, tracking of parts and materials and provides manufacturers with real-time insights into their production processes. RFID applications are gaining momentum in the passenger tyre segment, having already demonstrated numerous benefits in commercial applications.

Digitalisation technologies help quick identification of production defects in the final product and increase productivity with AI based scanning, inspection, real-time decision-making processes.

Digitalisation in the tyre industry is a gradual process that will improve performance, quality and profitability being on the way of real Industry 4.0 applications in tyre manufacturing. It continually opens up new opportunities to leverage data for better decision-making. Overall, digitalisation in tyre manufacturing is a powerful tool that unlocks the full potential of production. However, after implementation, continuous investment, as well as internal research and improvements, are required.

The tyre manufacturing industry is constantly evolving. Machines are becoming increasingly automated, more precise and data-driven. Recent advances based on the principles of Industry 4.0 include the aforementioned IoT, AI (artificial intelligence), robotics and sustainability.

Industry 4.0-driven digitalisation is based on the concept of the ‘digital twin’, meaning every machine is a data node. Data from every step (compound parameters, component dimensions, curing profiles) is collected for each tyre. This creates a virtual replica of the physical tyre, which is a ‘digital twin’ that enables complete traceability and data-driven process optimisation.

The role of humans is evolving from simple manual tasks to monitoring, diagnostics and data analysis. Robots, especially collaborative robots or cobots,

are taking over tasks such as final inspection and material handling. These revolutionary steps and concepts are having a major impact on manufacturing, optimising quality, performance, customer satisfaction and contributing to business success.

Modern mixing systems are increasingly replacing conventional tangential mixers. The intermeshing of the two rotors ensures more efficient and homogeneous mixing with better temperature control. This leads to higher mixing quality and consistency.

New mixing technologies, on the other hand, utilise ‘continuous mixing systems’, i.e. the continuous and simultaneous supply of all raw materials in precisely controlled quantities. The materials are continuously mixed in a series of specialised extruders and mixing units. At the end, a continuous stream of a perfectly homogeneous mixture emerges. This represents a revolution compared to conventional batch mixing. It improves energy efficiency, reduces the carbon footprint and enables unprecedented consistency and traceability.

Highly automated ‘multi-calender systems’ are equipped with multiple rollers that can simultaneously produce multiple layers (e.g. carcass ply, squeegee layer or inner liner) with extreme precision in thickness and width. Similar to extrusion lines with laser thickness control, these systems ensure 100 percent control and transmit data immediately to the extrusion head and calender roll clearances for automatic adjustment and maintenance of tolerances down to a fraction of a millimetre.

Thanks to the ‘multi-stage transfer’, the tyre casing is transferred between drums for the various production steps automatically and without human intervention, automatic cutting and splicing prevent deviations in quality. RFID technology integrated fully assures correct recipe and security in component application.

The robotic application and component preparation, such as with 6-axis robots, is now widely used for the fast and precise gripping and placement of complex components such as bead and apex assemblies.

Electric vulcanising presses are equipped with intelligent mould controls, whose integrated sensors monitor temperature and pressure in real time across multiple zones. The AI system dynamically adjusts the vulcanisation cycle (time, temperature, steam pressure) to ensure perfect curing of each tyre and compensate for any mould or material deviations.

Furthermore, predictive maintenance is now essential to avoid unplanned production downtime. Vibration, temperature and pressure sensors installed on manufacturing machines monitor all machine functions and alert when maintenance is required. High-precision servomotors, replacing pneumatic or hydraulic systems, work with servo-electric robots and are used in various production phases with submillimetre precision, reducing energy consumption and maintenance requirements.

The most visible technological advances in finishing and inspection lines today are fully automated with full sensitive cameras, AI-integrated and non-destructive testing (NDT) machines. Automated high-resolution X-ray machines scan each tyre to detect hidden defects such as trapped air, steel cord separation, or bead wire issues. Shearography and holography – being traditional but now equipped with intuitive, incredibly fast and precise modes – use lasers and intelligence to detect underlying defects or separations by measuring stress-induced deformations.

Uniformity and force variation measurement systems utilise AI algorithms to not only identify a tyre as ‘good’ or ‘bad’ but also diagnose the root cause of the deviation. Robotic trimming and polishing machines automatically locate and remove burrs (excess rubber) from the tyre using precise grinding tools – a traditionally manual and laborious task.

Of course, the future of tyre manufacturing, driven by advanced digitalisation, IoT and robotics, is rapidly evolving into a model for a smart, autonomous and sustainable industry, often referred to as ‘Tyre Industry 4.0’.

This transformation isn’t just about doing the same things faster; it will fundamentally change tyre design, production, sales and even performance. Tyre production facilities will become more autonomous, adaptable, efficient, predictive, personalised and, as expected, more sustainable.

Industry 4.0 and AI-powered digitalisation will accelerate sustainability. Precision manufacturing minimises material waste through the use of high-precision components. AI can easily manage energy consumption throughout the factory. IoT sensors monitor the overall condition of tyres, ensuring fast tyre changes, safety and performance.

This transformation will lead to safer, more efficient and more environmentally friendly tyres.

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ZC Rubber has received the Second Prize of China's State Science and Technology Progress Award for a project focused on high-performance tyre technologies and green intelligent manufacturing, developed jointly with Harbin Institute of Technology. The award recognises the project, titled Key Technologies and Green Intelligent Manufacturing of High-Performance Tires.

According to the company, ZC Rubber is the only Chinese tyre manufacturer to receive the State Science and Technology Progress Award at the Second Prize level or above during the past decade. The award is among China's highest state honours for scientific and technological innovation.

The company said the recognition reflects its investment in research and development and its efforts to integrate tyre development with intelligent manufacturing. In 2025, ZC Rubber invested RMB 1.54 billion in research and development, equivalent to 3.43 percent of annual revenue, according to its annual report.

The award recognises technologies that have moved beyond laboratory research into industrial application, linking high-performance tyre development with green and intelligent manufacturing processes.

Central to the company's research strategy are two proprietary technology platforms: the X-Tech System for truck and bus radial tyres and the Phecda Tech System for passenger car radial tyres. The platforms combine compound formulation, tyre structure design, process engineering, simulation, testing and intelligent manufacturing within a single development framework.

Rather than adapting an existing product architecture, the platforms define performance targets according to vehicle application, operating conditions and customer requirements before developing compounds, structures and manufacturing processes. ZC Rubber said this enables it to develop tyres for different duty cycles, climates, road conditions and regional requirements rather than using a standardised design.

Henry Shen, Senior Vice President of ZC Rubber, said: “Our objective is not simply to develop an individual material, tread pattern or manufacturing process. X-Tech and Phecda are complete development systems that connect user requirements with simulation, materials, tire engineering, manufacturing and validation. This award recognizes the direction we have pursued through sustained R&D investment.”

The company has applied the X-Tech and Phecda platforms across products developed for different regions. In Asia, the X-Tech System underpins the X-Elite truck tyre series. In Europe, it is used in the WESTLAKE Gen II commercial tyre range, while the Phecda Tech System supports passenger car tyres including the WESTLAKE ZuperAce Z-007 and GOODRIDE Solmax 1. Technologies from both platforms have also been applied across ARISUN's truck and passenger car tyre ranges in the Americas.

Shen said: “International markets do not have identical requirements. A tire developed for European highway fleets, Southeast Asian transport operations or passenger vehicles in the Americas must respond to different vehicles, roads, climates and customer priorities. Our technology platforms allow us to address those differences through a consistent and systematic development process.”

The company said the award-winning project incorporates green and intelligent manufacturing technologies intended to improve product consistency, production efficiency and energy performance. It added that the X-Tech and Phecda platforms will continue to support original equipment and replacement market product development across its WESTLAKE, GOODRIDE, ARISUN and other brands.

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The Indian Rubber Materials Research Institute (IRMRI) has officially announced the appointment of Professor (Dr) Abhijit Bandyopadhyay as its new Director. This decision marks a significant leadership transition for the institute, as it prepares to welcome a figure with extensive expertise in polymer science and rubber technology.

Professor Bandyopadhyay brings a distinguished academic and technical background to his new position. He currently serves as a full Professor in the Department of Polymer Science and Technology at the University of Calcutta and holds the role of Director, Technical at the South Asia Rubber and Polymers Park in West Bengal. His prior experience includes a tenure as Assistant Professor at the Rubber Technology Centre, IIT Kharagpur, and he has recently been appointed as a Technical Consultant for Rubber products at Berzelius Materials Performance Inc. in the United Kingdom.

Stepping into his new role, the new Director is expected to prioritise research advancement, indigenisation of technologies and sustainable development within the rubber sector. The IRMRI leadership and members have expressed confidence in his visionary guidance, anticipating that his leadership will drive the institute toward greater innovation and research excellence in the coming years.

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The Bureau of Indian Standards (BIS) has granted laboratory recognition to M/s D. Banerjee Centre of Excellence (DBCOE), based at the JSS Technical Institutions Campus in Mysuru, Karnataka, for a three-year period from 8 July 2026 to 7 July 2029.

The recognition, issued under the BIS Laboratory Recognition Scheme (LRS), enables the centre to undertake testing activities in accordance with BIS requirements. The laboratory's details have been uploaded to the BIS Laboratory Information Management System (LIMS), with sample receipt, testing and report generation to be managed through the online platform. The recognition remains subject to compliance with the provisions of the BIS LRS 2020.

Established by the Indian Institute of Rubber (IRI) in collaboration with JSS Technical Institutions, the centre is intended to strengthen industry-academia collaboration in polymer science and rubber technology while supporting research, testing, training and technology development for the tyre and wider rubber industry.

The facility has developed capabilities in material characterisation, wet chemistry and forensic failure analysis. Its laboratories can analyse raw materials including carbon black, rubber chemicals, elastomers, accelerators and antioxidants, while also supporting material specification development, plant audits and quality approvals. Plans are also in place to expand failure analysis services for manufacturers, particularly small and medium-sized enterprises (MSMEs).

DBCOE also aims to support manufacturers adapting to changing automotive requirements, including electric vehicles, through research into advanced materials and sustainable alternatives. Its stated focus includes bio-based materials, tyre recycling, steel reuse and low-emission polymers, alongside technical support for regulatory compliance and homologation.

Alongside its testing infrastructure, the centre has established a training ecosystem for the rubber sector. It offers two flagship programmes: a Diploma in Rubber Technology for diploma holders and new recruits, and a Postgraduate Diploma in Rubber Technology for science and engineering graduates. Both programmes combine online theory modules with practical training and laboratory sessions at the Mysuru campus, with final examinations conducted by IIT Kharagpur.

The centre is also developing a series of short-duration industry courses covering mixing, compounding, extrusion, calendering, tyre building, moulding, retreading, footwear, conveyor belts and latex products. These programmes combine classroom instruction with practical demonstrations, testing methodologies and failure analysis.

According to the centre, more than 40 industry experts contribute to its training programmes. Several tyre manufacturers, including Apollo Tyres, Yokohama, BKT and JK Tyre, recognise completion of the diploma programme as part of their employee development initiatives.

The centre primarily serves the tyre industry but also aims to support non-tyre rubber manufacturers, particularly MSMEs that lack access to advanced testing facilities and technical expertise. Through consultancy, training and laboratory services, it seeks to improve technical capability, product quality and compliance across the broader rubber sector.

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Elkem ASA, a global leader in advanced silicon-based materials, has announced the appointment of Dag Teigland as its new Chief Executive Officer, effective 3 August 2026. The board’s decision coincides with the departure of Helge Aasen, who will step down after leading the company since 2009 to take on the role of Chairman of the Board.

Bringing more than two decades of industrial and investment expertise, Teigland currently serves as executive chairman of Tekna Holding ASA, a firm known for advanced metal powders. His career includes senior executive positions at Tinfos AS and Holta Invest AS, where he managed an active investment platform. Previously, he held multiple leadership roles at Elkem from 1998 to 2002, culminating as Managing Director for the chrome business area, providing him with direct familiarity with the company’s operations.

Marianne E Johnsen, Interim Chair of the Board of Elkem, said, “The Board is pleased to appoint Dag Teigland as CEO of Elkem. He brings deep industrial expertise and a proven track record of driving development and transformation. With his background spanning both international industrial operations and investment environments, Dag is well suited to lead Elkem into its next phase of growth and development.

“At the same time, the Board would like to thank Helge Aasen for his strong leadership and significant contribution to Elkem over many years. During his tenure, Elkem has strengthened its strategic position, expanded its global footprint and developed world-leading positions in silicon, ferrosilicon, foundry alloys and carbon solutions. Helge has also led Elkem through major portfolio and financing measures, including the divestment of the Silicones division. We are very pleased that he will continue to contribute to the company’s development as chairperson of the board.”

Teigland said, “It is a great honour to return to Elkem and take on the role of chief executive officer. Elkem is a company with a strong industrial heritage and a leading position within its respective segments. I look forward to working with the Board, the Elkem leadership team and colleagues worldwide to build on this foundation, accelerate sustainable growth, advance safety and innovation and ensure that Elkem continues to supply the strategic materials needed for a cleaner, smarter and more resilient future.”

Aasen said, “It has been a privilege to lead Elkem as CEO over the past 17 years. I am proud of what the organisation has accomplished during this period and confident that the company is well positioned for long-term, sustainable value creation. I look forward to continuing to support Elkem in my new role as chairperson of the board and to work closely with Dag in the transition.”

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